Shipping carton for plush



Jan. 26, 1960 T. P. KESSLER SHIPPING CARTON FOR PLUSH 2 Sheets-Sheet 1 Filed May 8, 1956 INVE/VT'OR 76 THEODORE R KESSLER 2 Sheets-Sheet 2 Filed May 8, 1956 4 IPV. 7 2 m m w I. 5 f MW m Z I y g In mun 5 H w? 5 7 6 1 3 4 T v4 3 K I 2 n n I, 0 anal I 5 -i. A 6 f I I. l I m r 1 I I. H w n H I H H1 T I T l r W W T I 1 1 H 2 fl /u m 1 I l I 1 l H I 2 m h l I H i W :WJ, H I z (I r W F w H I 0 6 I, i

//vv/v r0 THEODORE R KESSLER A ,T/TORNEY United States Patent 2,922,516 I SHIPPING CARTON non PLUSH Theodore P. Kessler, Burlington, N.J., assiguor to Timron Development and Manufacturing Corporation, Bridgeboro, N.J., a corporation of New Jersey Application May 8, 1956, Serial No. 583,525 15 Claims. (Cl.- 206-51) cloth holding rack or reel is a part of the carton itself so that a rigid construction may be had affording greater freedom in handling with less danger of damage to the delicate piece goods.

A further object of the invention is to provide a container with minimum transverse cross-sectional area whereby a greater number of cartons of equal yardages may be shipped or stored in a given space .as these long pile goods are always shipped in upright position.

At thepresent time most piece fabrics of the kind mentioned are shipped on racks consisting of a rather sturdy central beam to Which-are attached substantial metal frames of hourglass shape, the four diagonals of which have strips of hook plates permanently fastened to them. These racks are satisfactory when first used although the initial cost is high. The racks, however, often wobble about a bit in their cartons or containers and therefore sometimes rupture the carton; also the normal life of the racks is very short, averaging between four to five shipments, because by that time the damage to the frame, the number of broken hooks, the rust, etc., make it cheaper to scrap the entire rack than to repair its parts. An additional disadvantage in the use of these racks is the cost of the return shipment together with the bookkeeping expenses involved in keeping track of the frames, which unfortunately frequently are lost or at least are not returned. -In my device the rack and the carton are firmly' secured together, as by means of staples, but when "delivered the carton portion may readily be cut loose from the loaded rack without unfastening the staples.

In the drawings:

Figure 1 is a perspective view of my carton ready for shipment.

Figure 2 is a central longitudinal section through one end of the carton, showing the assembly rod used when applying the cloth to the rack.

Figure'3 is a side view of the inner face of a panel 'or end board assembly showing the nearly square scroll line formed by the fabric when wound on the hooks of the rack.

Figure is a side view of the hook plate.

- Figure 5 is a section on line 55 of Figure 4.

Figure 6 is a section on line 6-6 of Figure 2. Figure 7 is a partial section on line 7-7 of Figure 8. V Figure 8 is an elevation of a modified form of reinforcing element.

My shipping carton includes two end board assemblies 10 each with a panel 11 having outwardly directed flanges 12 which are covered by and stapled to or otherwise secured to inturned lips 14, 15, 16, and 17 of the outwardly ice extending margins of sheet 20 which consists of four side panels 21, 22, 23, and 24. The outer carton sheet 20 of corrugated cardboard of 350 pound test is a square tube which may be closed at one side edge by integral outwardly extending flanges 26 and 27, bent outwardly from panels 24 and 21 respectively, and secured together after the plush is wound on the reel, as by stapling, riveting or any other manner. The 'end panel 11 is preferably of fiberboard approximately .07" thick, the flange 12 being formed eitherby bending four separate flanges along the usual crease lines or preferably by pressed formation in which case the four flanges are integral which makes a sturdier but more expensive construction. Fast centrally to the panel 11 of each end board assembly 10 is a reinforcing element consisting preferably of two similar hard wood members 30 and 31 forming an equal armed or Greek cross. This element may be made of drawn sheet metal with the inside face open whenever the cost of suitable wooden cross ends is greater. The two end assemblies form the heads of the cloth carrying rack'or, reel and are secured to the central tubular portion 20 or wrapper of the carton. In shipping and in storage the finished carton would rest on one or the other of the end assemblies and for this reason the outer face of the reinforcing element 30-31 is flush with the margin of the inturned bends 19 of the central portion or body of the carton.

Referring now to Figure 2, each end panel has an integral outwardly extending flange 12 all around its periphery and has sixteen holes arranged along the panel diagonals, such end panel preferably being square and quite rigid. The eight central holes are for the reception of screws 35 which secure the panel 10 to the reinforcing element formed by the blocks 30 and 31, and the outer eight holes are for tubular rivets 37 which hold the outer ends of the hook plates 40 (see Figures 4 and 5) to the end panels 11. The inner ends of these hook plates are secured by the screws 35 so that at their inner ends the hook plates are rigidly secured to the reinforcing element at each end. A bolt, such as 32, with a nut 33,- may be used in place of any of the screws 35 and will always be used when the reinforcing element is stamped from sheet metal, in which case the flat or open side of the element would be in contact with the fiberboard panel 11 and the nuts would be on the inside of the main web 45 of the hook plate 40.

The hook plates 40 are best illustrated in Figures 4 and 5. The major flange 41 of the plate carries the hooks 42 with their sharp points 43 directed inwardly or toward the short base web 45 of the plate. This web 45 is pierced with four holes, two near each end, the outer holes to receive the rivets 37 and the inner holes to receive the screws 35. The short flange 47 serves to strengthen th Web.

Figure 6 is a section looking at the inside face of panel I 11. The flanges 12, hidden in this view but indicated by the dashed line, extend away from the observer. The horizontal flange 12 is covered by panel 24 of sheet 20 and its integral lip 17 (indicated by the inner dashed line) of the bead of the carton and the similar flange 12 which is vertical in Figure 6 is covered by panel 21 of the carton and its inturned lip 14, the margin of both lips being substantially in contact with the outside face of the panel 11 of the end board assembly 10. The staples 50 are best shown in Figure 2, each extending through the panel of the carton, the flange of the end board panel 11, and the inturned lip of the carton bead. The flange 41 of book plate 40 is preferably exactly along the diagonal of the panel 11 and of the entire container. The tubular rivets 37 holding the base web 45 of the hook plate to the panel 11 are parallel to the-diagonal but very close to it. The

short flange 47, however, purposely extends slightly past the edge of the panel 11 and consequently the corner 52 of the hook plate projects beyond the margin of the panel 11 and is therefore imbedded in the outer panel of the, sheeti2ll 'just 'sufliciently not to tear through but-to insure additional supporting strength.

Referring again to Figure 2, the reel which holds the cloth is formed by the two end assemblies and a spacer 55 which is a mere tube of cardboard approximately three inches wider than the cloth to be mounted on the reel or rack, such cloth for instance being 54 /2" wide. When applying the cloth to the reel, means must be provided to hold the two end assemblies together.

For this purpose the reinforcing elements 3tl3 1, whether wood or metal, have central holes 57 through them. An assembly rod 60 is passed through these holes and somewhat larger holes 58 in the end panels 11. A trunnion 59 is threaded as at 61 to receive the end of the assembly rod 60 and this holds the two ends of the rack firmly against the cardboard sleeve or tube 55 until the clothis in place, after which the cloth itself holds the end boards together. The empty rack is placed in the usual holding fixture, not shown, which has open journal hearings in which the two trunnions 59' may revolve. The selvage of the piece goods is now caught in the hooks beginning nearest the spacer in the usual fashion to form a helix of substantially square convolutions, as shown in Figure 3. The rack may readily be rotated as the cloth is wound on it.

-When the yard goods is completely attached to the reel and without removing the reel from the holding fixture, the carton sheet 20 is applied. It is first closed to forma square box or tube by stapling together the flanges 26 and 27. The two side edges of each panel of the carton wrapper, sheet 20, now extend well beyond the flanges 12 of end panels 11 on both sides. These panel ends of sheet 20 are first bent transversely along preformed creases 70 to form the head or rounded edge 19 of the carton, and'the four lips 14 to 17 are then bent parallel to their panels along previously creased lines 71 :so that the margin of each lip engages or is close tothe outside face of the end panel 11. These beads formed ofthe carton panel, the end panel flange, and the inturned lip of the cartonpanel are then stapled all around on both sides of the container and theassemblcd carton may now be taken from the fixture and one or both of the trunnions 59 may be removed from the in any way the various staples 50 as they remain in. the severed beads 19 which are now carried by the end panels 11, the flange 12 of which is the central layer of the bead, these severed portions not being in the way at all when removing the plush from the reel or rack as they are on the outside of-the heads of the-reel, while the. cloth is between the heads.

A convenientform of the reinforcing element when made of metal is shown in Figures 7 and 8. A square piece of sheet metal 'Mis dished to a dome shape as at -75 but with four flat portions 76 lying in the plane of h What I claim is:

1. A hook plate for a plush rack, roughly J-shaped in cross section having a perforated base web for attachment to a rack panel, a short strengthening flange, and a major flange parallel thereto, said major flange carrying a series of pointed hooks, whereby the bottom of the hook plate is channel shaped in crosssection and therefore its two flanges add material stiffness to an .end panel to which the plate is secured. A 1

2. A rack for pile fabric piece goods comprising a pair of square end panels of sheet material, each having diagonally positioned hook- 'plates secured thereto, a roll of pile fabric goods mounted ontherack, a hollow tube frictionally engaging the two end panels to prevent them from approaching each other, said tube being held against the two end panels by the goods supported in substantially square convolutions by the hooks of the plate, said end panels each having four outwardly extending flanges in combination 'with-anopen ended carton box of four side panels, each panel of which is secured ateach end to said flanges of the end panels so that the box and the end panels form a shipping carton.

3. The combination of claim 2 in which the. side panels have reversely bent lips enclosing the end panel flanges.

4. A carton comprising an open ended corrugated cardboard box of four equal side panels and a rack with end panels each having an outwardly extending continuous flange fastened to all four of the box panels, a roll of pile goods supported by the rack and a reinforcing element secured centrally to the outside face of each end panel with its outermost surface flush with the bead margins of the box panels whereby to give firm support to the rack contents when the carton stands with one of the endpanels uppermost.

5. :A combination shipping case and reel for pile fabrics comprising a sheet of readily cuttable corrugated paper board consisting of fourequal side panels and a flange extendingfrom the two outside. panels, the two flanges beingfastened together to form the sheet into a hollow tube, square in cross section, with the flangesback to back and extendingaway from the axis of the hollow tube, apair'of reel heads relatively more rigid than the paper board and of asizc tofit snuglyinside the hollow tube, means forzsecuring the two heads to the tube at the open ends thereof, spacing means holding the two heads apart, a series of plush holding hook plates secured approximately radiallyto the inside face of each reel head, and a roll of pile fabric wound in convolutions on the hook plates and holding the reel headsfirmly against the spacing means, whereby when the combined reel and case is received by a purchaser, the two flanges extending from proximate panels of the hollow tube may be cut loose from the tube without separating the, two flanges, and the tube may readily be severed with a knife near the margins of the two reel heads without disconnecting said securing means securing the two heads to the hollow tube, and thus allow the throwing away of the severed tube, leavingthe reel-with itsthereby-carried pile fabric ready for removal of fabric as needed. v 6. The combination of claim 5 in whicheach head has a-peripheral outwardly extendingflange alined with the margin of thetube and secured thereto.

7. Acombination shipping case and reel for pile fabrics comprising a sheet of corrugated paper board of a type to be readily cut by a knife, said sheet comprising equal side panels forming a hollow tube, a pair ofreel heads of a size to fit the inside of the hollow tube, means for securing the heads to the open ends of the tube, spacing means holding the two heads apart, a series of fabric holding hook plates secured to the inside face of each reel head and spaced apart to form a socket snugly receiving and positioning said spacing means, and a roll of pilefabric wound in-convolutions on the series of hook plates and resiliently holding the heads in contact with the spacing means.

8. The device of claim 7 in which a dished metal reinforcing element engages the outer face of each reel head and is secured thereto and to the inner end of each hook plate.

9. In combination, a reel comprising a pair of reel ends each carrying a plurality of hook plates to support convolutions of cloth and a spacing means between the two ends; a roll of pile goods carried by the supporting means with the adjacent piles separated, said goods by its widthwise tension holding the two reel ends against the spacing means, and a wrapper secured to both of the two ends and completely enclosing the roll of goods to form with the loaded reel a shipping carton.

10. A shipping container for pile goods comprising an outer carton sheet or wrapper of corrugated paper forming a tube, open at both ends, a reel inside of the tube and including two reel ends each. carrying a generally radial series of hook plates and a central member engaging both reel ends, a roll of pile goods wound in spaced convolutions on the several hook plates, means securing the end margins of the corrugated paper tube to the two reel ends outwardly of the inside surface of the reel ends, whereby when the container arrives at its destination the contents may readily be exposed by removing the portion of the wrapper between the reel ends by slitting the Wrapper longitudinally from reel end to reel end and cutting the tube around transversely proximate to but outwardly of the hooks of the hook plates.

11. The container of claim 10 in which the tube is square in cross-section, the reel ends are outwardly flanged, the ends of the tube are reversely bent around the reel end flanges so that the flanges and the portions of the Wrapper outward of the reel ends form a continuous beaded carton edge of three thicknesses, the entire beaded edge of each head remaining fastened to the reel head when the wrapper is severed but lying outward of each reel head and therefore not interfering with the pile goods as it is detached from the hooks.

12. A panel assembly to form one end of a one-trip shipping container for piece goods, the layers of which should be kept from contact with each other, comprising a rectangular one-piece panel of fibrous sheet material, four hook plates secured to the panel, each hook plate extending from a corner of the panel to a point in line with but short of the center of the panel, and a plurality of spaced fastening means extending through the panel to secure each plate firmly to the panel, whereby to 6 give rigidity to the panel when the container is loaded with piece goods attached to the several hook plates at each end.

13. The device of claim 12 in which the panel is square, the hook plates are spaced apart and the square panel is further strengthened against bending by a peripheral, integral, outwardly extending, right angular flange on the side of the panel opposite the hook plates.

14. The panel assembly of claim 12 with a tubular wrapper surrounding the panel assembly, a portion of each hook plate extending slightly beyond the margin of the panel whereby to penetrate the wrapper and aid in resisting movement of the end panel with respect to the wrapper.

15. A rack for pile fabric piece goods comprising a pair of rectangular end panels of sheet material each with four outwardly extending flanges, four diagonally positioned hook plates rigidly secured to each end panel on the side opposite the flanges to strengthen the end panels and to hold said piece goods, a hollow tube frictionally engaging the two end panels, a trunnion at each end of the rack and a tension member passing centrally through the rack and releasably connecting the two trunnions so as to hold the end panels against the hollow tube while the goods is being wound on the four hook plates, the tension member to be removed when the goods are wound on the hook plates and therefore hold the end panels together by widthwise tension.

References Cited in the file of this patent UNITED STATES PATENTS 179,161 Conquest June 27, 1876 499,774 Bancroft June 20, 1893 523,523 HOX July 24, 1894 1,297,751 Thornton Mar. 18, 1919 1,677,515 Durand July 17, 1928 2,056,808 Skar Oct. 6, 1936 2,253,788 Kern Aug. 26, 1941 2,315,532 Lucia Apr. 6, 1943 2,326,817 Zalkind Aug. 17, 1943 2,341,374 Gardner Feb. 8, 1944 2,356,787 Hellyar Aug. 29, 1944 2,543,507 Rancourt Feb. 27, 1951 2,548,390 Pendleton Apr. 10, 1951 FOREIGN PATENTS 50,128 Germany Oct. 10, 1911 295,196 Great Britain Aug. 9, 1928 

